Apparatus and methods for forming a butt splice on a running web

ABSTRACT

Methods are provided for forming a butt splice to join a first web of material to a second web of material is provided. The first web of material is cut or trimmed to form a first edge. The second web of material is cut or trimmed to form a second edge, and the second edge is positioned with respect to and registered with the first edge to define a gap therebetween. A curable liquid adhesive, such as an ultraviolet (UV)-curable liquid adhesive, is dispensed or applied within the gap, and the liquid adhesive is cured to form the butt splice that joins or splices the first web of material to the second web of material.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application Ser.No. 61/773,913 filed Mar. 7, 2013, the entire disclosure of which ishereby incorporated by reference herein.

BACKGROUND

The subject matter disclosed herein relates generally to joiningtogether a leading edge of a newly prepared web from a new roll ofmaterial to a trailing edge of a web from an expiring roll of materialthat is being fed to a continuous web processing operation and, moreparticularly, to an apparatus and methods for forming a butt splice tojoin the webs using a UV-cured liquid adhesive applied within a gapformed between the leading edge of the web from the new roll of materialand the trailing edge of the web from the expiring roll of material.

Various apparatus and methods for joining or splicing webs used incontinuous web processing operations are known in the art. One commonmethod of joining web materials is a lap splice, wherein a leading edgeof a new web is treated with a suitable adhesive, and at a proper timeis manually lapped over a trailing edge of an expiring roll. U.S. Pat.No. 4,519,858 describes an apparatus and method for making such lapsplices. Drawbacks to the lap splice include an undesirable doublethickness of material at the splice, which is particularly unsuitablefor relatively thick web materials. Further, because of restrictiveoperations downstream of the splice, certain types of materials,including two-ply pressure sensitive label stock, cannot be spliced in alap splice.

Another common method of joining webs is through the use of a buttsplice. With a butt splice, the leading edge of the new roll is buttedup against, but does not overlap, the trailing edge of the expiringroll. A relatively thin, single-sided piece of adhesive tape is thenused to join the butted ends together. In the past, hand operations havehad to be used to achieve a good-quality butt splice. Typically, a goodquality butt splice has less than a one/one thirty-second inch gapbetween the butted ends of the webs that are being joined. The accuracyrequired has necessitated the stoppage of the running web from theexpiring roll for a sufficient time to make a hand splice. However, aseach roll expires, such stoppage results in significant loss ofproduction time. More recently, automated machines and methods have beendeveloped to quickly and accurately join webs through the use of anadhesive tape to form the butt splice. See, for example, U.S. Pat. No.7,022,205. However, in some conventional butt splicing machines andmethods, the adhesive tape undesirably increases a thickness of thesplice. Moreover, the adhesive tape may not adequately adhere to certainweb materials, such as web materials coated with grease-proof,water-proof, or vapor deposition coatings, for example.

SUMMARY

In one aspect, an apparatus and methods for forming a butt splice tojoin a first web of material to a second web of material is provided.The first web of material is cut or trimmed to form a first edge. Thesecond web of material is cut or trimmed to form a second edge, and thesecond edge is positioned with respect to and registered with the firstedge to define a gap therebetween. A curable liquid adhesive, such as anultraviolet (UV)-curable liquid adhesive, is dispensed or applied withinthe gap, and the liquid adhesive is cured to form the butt splice thatjoins or splices the first web of material to the second web ofmaterial.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of an exemplary web splicer;

FIG. 2 is a top plan view of the web splicer shown in FIG. 1;

FIG. 3 is a top plan view of an exemplary splicing apparatus for the websplicer;

FIG. 4 is a schematic illustration of threaded rolls of web material inan exemplary web splicer;

FIG. 5 is a schematic front view of an exemplary splicing assembly forforming a butt splice to join a leading edge of a new web of material toa trailing edge of an expiring web of material;

FIG. 6 is a schematic side view of a portion of the splicing assemblyshown in FIG. 5, illustrating exemplary light sources suitable forcuring a UV-curable liquid adhesive within a gap defined between the newweb of material and the expiring web of material;

FIG. 7 is a schematic front view of an exemplary splicing assembly forforming a butt splice to join the leading edge of a new web to thetrailing edge of an expiring web;

FIG. 8 is a schematic side view of a portion of the splicing assemblyshown in FIG. 7, illustrating exemplary light sources suitable forcuring a UV-curable liquid adhesive within a gap defined between the newweb of material and the expiring web of material;

FIG. 9 is a schematic view of a roll unwind stand, an exemplary websplicer, and a festoon;

FIG. 10 is an enlarged side elevation view of the web splicer shown inFIG. 9;

FIG. 11 is a top plan view of the splicer shown in FIG. 10;

FIG. 12 is a cross-sectional view taken along the line 12-12 in FIG. 11;

FIG. 13 is an enlarged view of the part of the web splicer designated bythe line 13 in FIG. 12;

FIG. 14 is an enlarged, partial perspective view of the web cutting andadhering assembly of the web splicer shown in FIG. 9;

FIG. 15 is a perspective view of the exit end of the web splicer shownin FIG. 9;

FIG. 16 is an enlarged, partial side elevational view of the upper partof the web splicer shown in FIG. 9 showing, with parts broken away, theleading portion of the new web being fed into the web splicer;

FIG. 17 is an enlarged partial side elevational view of the upper partof the web splicer shown in FIG. 9 and showing the web preparationassembly in its first position to trim the leading end of the new web;

FIG. 18 is an enlarged, partial side elevational view of the new webholding assembly of the web splicer shown in FIG. 9;

FIG. 19 is a partial side elevational view, similar to that of FIG. 18,but showing the web holding assembly in its second or lower position;

FIG. 20A is a front view of a first web of coated film material joinedor spliced to a second web of coated film material by a butt spliceaccording to one embodiment disclosed herein;

FIG. 20B is an opposing rear view of the spliced webs shown in FIG. 20A;

FIG. 21A is a front view of a first web of coated cardboard materialjoined or spliced to a second web of coated cardboard material by a buttsplice according to one embodiment disclosed herein;

FIG. 21B is an opposing rear view of the spliced webs shown in FIG. 21A;

FIG. 22A is a front view of a first web of fiberglass material joined orspliced to a second web of fiberglass material by a butt spliceaccording to one embodiment disclosed herein;

FIG. 22B is an opposing rear view of the spliced webs shown in FIG. 22A;

FIG. 23A is a front view of a first web of porous cardboard materialjoined or spliced to a second web of porous cardboard material by a buttsplice according to one embodiment disclosed herein; and

FIG. 23B is an opposing rear view of the spliced webs shown in FIG. 23A.

DETAILED DESCRIPTION

The embodiments described herein relate to an apparatus and methods forforming a butt splice to join a leading edge of a newly prepared web ofmaterial from a new roll of material (referred to herein as a “new web”)to a trailing edge of a web of material from an expiring roll ofmaterial (referred to herein as an “expiring web”) that is being fed toa continuous web processing operation. The methods described hereininclude both a linear process and a monolithic process for forming thebutt splice using an ultraviolet (UV)-curable liquid adhesive appliedwithin a gap formed between the leading edge of the new web and thetrailing edge of the expiring web.

The embodiments described herein are suitable for joining webs formed ofsuitable materials including, without limitation, one or more of thefollowing materials: film, coated film or material, fiber, fiberglass,paper including cardboard, nonwoven web, woven web, and other suitablematerials and combinations thereof known to those having ordinary skillin the art. Moreover, although this disclosure describes the use of aUV-curable liquid adhesive to form the butt splice, other suitableadhesives known to those having ordinary skill in the art may also beused to form a sufficiently strong butt splice.

In one aspect, a method of forming a butt splice includes a linearprocess, as described in greater detail below, wherein the leading edgeof the new web and the trailing edge of the expiring web are cut ortrimmed and temporarily immobilized, a UV-curable liquid adhesive isapplied within a gap formed between the leading edge of the new web andthe trailing edge of the expiring web, and the liquid adhesive is curedusing a suitable UV-curing light source, such as one or more suitablelight emitting diodes (LEDs), to form a sufficiently strong butt splice.

In another aspect, a method of forming a butt splice includes amonolithic process, as described in greater detail below, wherein theleading edge of the new web is cut or trimmed and temporarilyimmobilized, the trailing edge of the expiring web is cut or trimmedusing a shear blade extending from a splicer assembly, a UV-curableliquid adhesive is dispensed from an adhesive applicator manifolddefined in the splicer assembly and applied within a gap formed betweenthe leading edge of the new web and the trailing edge of the expiringweb, and the liquid adhesive is cured using a suitable UV-curable lightsource, such as one or more suitable LEDs, to form a sufficiently strongbutt splice.

Referring now to the drawings, wherein like reference numerals denotelike or corresponding parts throughout the drawing figures, andparticularly to FIGS. 1-8, the apparatus and methods as described hereinare particularly suitable for use with a web splicer 10 configured for acontinuous web processing operation, whereby a leading edge of a webfrom a new roll of material and a trailing edge of a web from anexpiring roll of material are both trimmed or cut and subsequentlyjoined together via a butt splice. Web splicer 10 includes an unwindstand 12, a splicing apparatus 14, and a storage festoon 16. Rolls ofweb material 18, 20 are placed onto spindles 22, 24 of unwind stand 12.Unwind stand 12 also includes at least one idler roller 26, 28 for eachspindle 22, 24. The web material that is mounted onto spindle 22, 24 isrouted around associated idler roller 26, 28 and towards splicingapparatus 14. The web material is then threaded between entrance rollers30, 32, as shown in FIG. 4, and into splicing apparatus 14.

As shown in FIG. 3, splicing apparatus 14 includes an anvil 30positioned between splicing assemblies 34, 35 and substantially parallelto end members 36 of a splicer frame 38. On both sides of anvil 30 arepivotable nip rolls 40, 41. When in an open position, nip rolls 40, 41permit the web of material to pass along the sides of anvil 30. However,when a web of material is to be trimmed or cut, respective nip roll 40,41 located adjacent to that web of material is pivoted via activation ofassociated power cylinders 42 to a closed position against anvil 30,whereby nip roll 40, 41 holds the web of material during the splicingoperation, described below.

The new web may be manually pulled until the new web threaded throughsplicing apparatus 14 is taut, at which time nip roll 40 adjacent to thenew web is pivotably moved to a closed position to secure a portion ofthe new web against anvil 30. The activation of nip roll 40 may beachieved by the movement of a shear wheel assembly 44, for example. Thismovement activates a sensor such as a whisker valve that actuates powercylinders 42 that are operably connected to nip roll 40 that is adjacentto the new web to be trimmed or cut. Nip roll 40 is then pivoted to aclosed position, whereby nip roll 40 secures a portion of the new webagainst anvil 30.

The linear movement of shear wheel assembly 44 towards and across thenew web that is secured against the adjacent first side of anvil 30 mayoccur via an operator manually moving shear wheel assembly 44.Alternatively, shear wheel assembly 44 may be connected to a doubleacting pneumatic cylinder or other suitable automation mechanism,whereby the activation of the pneumatic cylinder initiates the linearmovement of shear wheel assembly 44 across anvil 30 and the secured newweb.

As shear wheel assembly 44 moves from an initial first position to asecond position across a width of the new web, a shear wheel 46 rotatesto trim or cut a leading edge of the new web. After shear wheel 46 hascompletely run across the leading edge of the trimmed web material, andshear wheel assembly 44 has reached its second position against a stop48, the excess cut or trimmed web material is removed. The leading edgeof the trimmed new web is now substantially even with or congruent tothe cutting edge of anvil 30. Once the leading edge has been trimmed,shear wheel assembly 44 may be returned from its second position to itsinitial first position.

In preparation for trimming the trailing edge of the expiring roll, theoperator must make a decision as to when to initiate the splicing of thetrailing edge of the expiring web. Once this decision is made, theoperator pushes a switch that activates power cylinders 42 that areoperably connected to nip roll 41 adjacent to the expiring web. Nip roll41 is then pivoted to a closed position to secure a portion of theexpiring web against anvil 30. Once secured, splicing assembly 35adjacent to the expiring web is actuated to begin the splicing processto join the leading edge of the new web to the trailing edge of theexpiring web.

Referring further to FIGS. 5 and 6, in one embodiment, splicing assembly135 forms a butt splice to join together the leading edge of the new weband the trailing edge of the expiring web, as the expiring web runsdownstream under tension along a predetermined path of travel. As shownin FIGS. 5 and 6, a leading edge 102 is formed on a new web of material104 by splicing or cutting the new web 104. Once new web 104 is cut orspliced, new web 104 is temporarily secured against a surface of ananvil 30 by nip 40. With leading edge 102 secured against anvil 30,expiring web 110 is temporarily secured against anvil 30 by nip 41. Withboth new web 104 and expiring web 110 secured against anvil 30, splicingassembly 135 is moved laterally across a width of expiring web 110.Splicing assembly 135 includes a shear wheel 116, an adhesive applicator118, and a curing device 120 including one or more UV-curing lightsources. As splicing assembly 135 moves across expiring web 110, shearwheel 116 cuts or trims expiring web 110 to form a trailing edge 122along the cutting edge of anvil 30.

Trailing edge 122 is registered with leading edge 102 to define a gap124 between leading edge 102 and trailing edge 122 along a width of newweb 104 and a width of expiring web 110. In one embodiment, gap 124 isnot greater than 1 millimeter (mm); however, in alternative embodimentsgap 124 may exceed 1 mm and may be, for example, not greater than 2 mm.With each of leading edge 102 and trailing edge 122 secured againstanvil 30 by associated nip 40, 41, adhesive applicator 118 dispenses acontrollable amount of UV-curable liquid adhesive 126 within gap 124. Incertain embodiments, adhesive applicator 118 includes a needleapplicator to facilitate accurately dispensing a desired quantity ofliquid adhesive in a desired area within gap 124. As shown in FIG. 5,adhesive applicator 118 is operatively coupled to shear wheel 116 suchthat adhesive applicator 118 moves across expiring web 110 with shearwheel 116. Adhesive applicator 118 is controlled using a suitablecontroller (not shown) to dispense a precise quantity of adhesive asadhesive applicator 118 moves along a length of gap 124 between a firstlateral edge 128 of expiring web 110, substantially parallel to alongitudinal axis 130 of expiring web 110, and an opposing secondlateral edge 132 of expiring web 110, as shown in FIG. 5.

Curing device 120 is operatively coupled to adhesive applicator 118 suchthat curing device 120 follows adhesive applicator 118 along gap 124 tocure adhesive 126 dispensed in gap 124. In one embodiment, curing device120 includes one or more ultraviolet (UV) light sources 134 as shown inFIG. 6, such as light emitting diodes (LEDs), configured to emit UVlight at a suitable intensity to cure adhesive 126 within a desiredtime. In a particular embodiment, light sources 134 are offset withrespect to a z-axis 134 normal to longitudinal axis 128, as shown inFIG. 6, to allow for better visibility of gap 124 and adhesive 126and/or to accommodate off-gassing during the curing process, forexample. In an alternative embodiment, curing device 120 includes one ormore light sources 134 that are fixed or stationary with respect toexpiring web 110 and directed onto an area in which adhesive 126 isdispensed or applied such that after adhesive applicator 118 movesacross gap 124, light sources 134 are activated to emit UV light at asuitable intensity to cure adhesive 126 within a desired time. Forexample, a wattage output of each light source 134 within curing device120 is controllable to emit UV light at an intensity suitable to cureadhesive 126 within a set time. In this embodiment, light sources 134may also be controlled by a timer or other suitable controller (notshown) such that light sources 134 are activated to emit light onlyduring the curing process.

Once adhesive 126 is cured, a sufficiently strong butt splice 140 isformed, as shown in FIG. 6, to join new web 104 to expiring web 110.Nips 40, 41 are then released to allow the joined webs to movedownstream. In one embodiment, once splicing assembly 135 has cut theexpiring web, a sensor, such as a whisker valve, deactivates nips 40, 41so that the newly spliced web may run through the remainder of websplicer 10 and towards storage festoon 16.

Referring further to FIGS. 7 and 8, in an alternative embodiment,splicing assembly 235 forms a butt splice to join together the leadingedge of the new web and the trailing edge of the expiring web, as theexpiring web runs downstream under tension along a predetermined path oftravel. As shown in FIGS. 7 and 8, leading edge 102 is formed on new webof material 104 by splicing or cutting new web 104. Once new web 104 iscut or spliced, new web 104 is temporarily secured against anvil 30 bynip 40, as shown in FIG. 8, to facilitate joining new web 104 toexpiring web 110. With leading edge 102 secured against anvil 30, in oneembodiment, expiring web 110 is temporarily secured against anvil 30 bynip 41. With both new web 104 and expiring web 110 secured to anvil 30,splicing assembly 235 is moved, such as in a vertical gravity drop,towards expiring web 110 registered with new web 104. In thisembodiment, splicing assembly 235 includes a shear blade 216 and anadhesive applicator manifold 218. In one embodiment, a curing device220, including one or more UV-curing light sources 222 as shown in FIG.8, is positioned with respect to a support surface of anvil 30 on whicheach of new web 104 at leading edge 102 and expiring web 110 at trailingedge 122 is supported. As splicing assembly 235 moves through expiringweb 110, shear blade 216 cuts or trims expiring web 110 to form atrailing edge 122. Trailing edge 122 is registered with leading edge 102to define gap 124 between leading edge 102 and trailing edge 122 along awidth of new web 104 and a width of expiring web 110. In one embodiment,gap 124 is not greater than 1 mm; however, in alternative embodimentsgap 124 may exceed 1 mm and may be, for example, not greater than 2 mm.

As shearing blade 216 passes through expiring web 110, one or more stops224, shown in FIG. 7, are positioned under anvil 30 to stop or preventfurther movement of shearing blade 216 and facilitate accuratelypositioning adhesive applicator manifold 218 over gap 124 definedbetween leading edge 102 and trailing edge 122. With each of leadingedge 102 and trailing edge 122 secured by respective nip 40, 41,adhesive applicator manifold 218 dispenses a controllable amount ofUV-curable liquid adhesive 126 within gap 124. In certain embodiments,adhesive applicator manifold 218 includes one or more needle applicatorsto facilitate accurately dispensing a desired quantity of liquidadhesive in a desired area within gap 124. In one embodiment, adhesiveapplicator manifold 218 is controlled using a suitable controller (notshown) to dispense a precise quantity of adhesive as adhesive applicatormanifold 218 is positioned over a length of gap 124 between a firstlateral edge 128 of expiring web 110 and second lateral edge 132 ofexpiring web 110.

As shown in FIG. 8, curing device 220 includes one or more UV-curinglight sources 222 positioned on opposing lateral sides of gap 124. Inthis embodiment, each light source 222 is fixed or stationary withrespect to expiring web 110 and directed onto an area in which adhesive126 is dispensed or applied such that after adhesive applicator manifold218 dispenses adhesive 126 and is retracted, such as in an upwarddirection, to an initial position, light sources 222 are activated toemit UV light at a suitable intensity to cure adhesive 126 within adesired time. For example, a wattage output of each light source 222within curing device 220 is controllable or selectable to emit UV lightat an intensity suitable to cure adhesive 126 within a set time. In thisembodiment, light sources 222 may also be controlled by a timer or othersuitable controller (not shown) such that light sources 222 areactivated to emit light only during the curing process. In oneembodiment, curing device 220 includes one or more ultraviolet (UV)light sources 222 as shown in FIG. 8, such as LEDs, configured to emitUV light at a suitable intensity to cure adhesive 126 within a desiredtime. In a particular embodiment, light sources 222 are offset withrespect to a z-axis 134 normal to longitudinal axis 128, as shown inFIG. 8, to allow for better visibility of gap 124 and adhesive 126and/or to accommodate off-gassing during the curing process, forexample. In alternative embodiments, curing device 220 is operativelycoupled to adhesive applicator manifold 218 such that curing device 220moves with adhesive applicator manifold 218 towards gap 124 to cureadhesive 126 dispensed in gap 124.

Once adhesive 126 is cured, a sufficiently strong butt splice 140 isformed to join new web 104 to expiring web 110. Nips 40, 41 are thenreleased to allow the joined webs to move downstream. In one embodiment,once splicing assembly 235 has cut expiring web 110 and reaches itsinitial position, a sensor, such as a whisker valve, deactivates nips40, 41 so that the newly spliced web may run through the remainder ofweb splicer 10 and towards storage festoon 16.

The rate at which butt splice 140 is formed according to the embodimentsdescribed herein is controlled, at least in part, by one or more of thefollowing steps: splicing or cutting new web 104 to form leading edge102; splicing or cutting expiring web 110 to form trailing edge 122;applying or dispensing adhesive 126; allowing suitable time for adhesive126 to spread within gap 124 and/or diffuse or wick into webs 104 and110, as desired; and curing adhesive 126 to form butt splice 140. Theability to control the rate at which butt splice 140 is formed is highlyadvantageous when expiring web 110 continues to move through thedownstream web processing machine as new web 104 is joined or spliced toexpiring web 110.

Referring to FIGS. 9-19, the apparatus and methods as described hereinare particularly suitable for use with a web splicer 310 configured fora continuous web processing operation, whereby a leading edge of a newlyprepared web of material from a new roll of material or a “new web” to atrailing edge of a web of material from an expiring roll of material oran “expiring web” are both trimmed or cut and subsequently joinedtogether via a butt splice.

An expiring web 314 is supported on a conventional turret type, rollunwind stand, shown generally at 318. As shown in FIG. 9, expiring web314 moves along a substantially horizontal path of travel to web splicer310 while supported on one end of a conventional unwind arm assembly322. Unwind arm assembly 322 is connected, midway between its ends, tounwind stand 318 and is adapted to be selectively pivoted about itspoint of connection with unwind stand 318. A new web 324 is supported onthe other, opposite end of unwind arm assembly 322. Conventional rollbraking means, not shown, are included on the ends of unwind armassembly 322 and may, upon receipt of a signal, be utilized to stop therotation of the rolls and thus stop the webs from running off the rolls.

New web 324 is led to web splicer 310 in preparation for a splice. Whenthis is done, the path of travel of new web 324 to web splicer 310 is atan angle to the horizontal. After a splice has been made, such thatexpiring web 314 is no longer being fed to web splicer 310, another newroll of material will then be supported on the one end of unwind armassembly 322 in place of expiring web 314. Thereafter, new web 324 willbe moved to the position now occupied by expiring web 314 and the othernew roll will be supported where new web 324 is shown in FIG. 9.

As noted above, expiring web 314 moves along a substantially horizontalpath of travel to and through web splicer 310. More specifically,expiring web 314 enters web splicer 310 by passing around an entranceidler roll 328 mounted on web splicer 310. Thereafter, expiring web 314passes around an exit idler roll 332 mounted on web splicer 310 adjacentto its exit end. Expiring web 314 is directed downwardly from idler roll332 to a second exit roll 334 mounted between two legs 312 of websplicer 310. Expiring web 314 is then directed along a generallyhorizontal path to entrance roll 336 in a festoon 338. Upon exiting fromfestoon 338, expiring web 314 travels to a web utilization apparatuswhich may be, for example, a printing press, not shown.

Festoon 338 is of conventional design and construction. It acts as anaccumulator for running expiring web 314 such that the web utilizationapparatus does not have to be stopped when the portion of expiring web314 in web splicer 310 is stopped during a splicing operation. Festoon338 includes upper and lower sets of rolls 342 and 344, respectively,about which expiring web 314 passes. When the portion of expiring web314 in web splicer 310 is stopped, upper set of rolls 342 movesdownwardly toward lower set of rolls 344.

A horizontal platform 346 is mounted between web splicer 310 and festoon338. Platform 346 may be used by the operator while preparing new web324 for a splice. A step 348, adjacent to platform 346, assists theoperator in climbing up and down from platform 346.

Referring now to FIGS. 10, 11 and 15, web splicer 310 includes twoparallel, spaced apart side plates 352 and 354. The upper ends of legs312 are secured to side plates 352 and 354. The ends of idler rolls 328and 332 are journaled in side plates 352 and 354. A pair of brackets 356are fastened, at lower ends, to upper, upstream corners of plates 352and 354 adjacent to the entrance end of web splicer 310. The other,upper ends of brackets 356 project upwardly a short distance. The endsof an idler roll 358 are journaled in the upper ends of brackets 356.New web 324 passes around idler roll 358 as it travels into web splicer310, as shown in FIG. 9.

As illustrated in FIG. 10, web splicer 310 includes a nip assembly 362,a new web preparation assembly 364, a new web holding assembly 366, anda web cutting and adhering assembly 368, as described in detail herein.Nip assembly 362 serves to clamp expiring web 314 to and about idlerroll 332 during a splicing operation. New web preparation assembly 364is used to prepare the leading end of new web 324 for the splicingoperation. New web holding assembly 366 is used to hold a portion of newweb 324, immediately upstream of its leading end, in preparation for thesplicing operation and during the splicing operation itself. Web cuttingand adhering assembly 368 cuts or shears expiring web 314 during thesplicing operation and causes the cut part of the trailing end ofexpiring web 314 and the leading end of new web 324 to be joined asexpired web 314 is cut.

Assemblies 364, 366, and 368 are mounted on side plates 352 and 354, aswill be described, and extend across web splicer 310 from side plate 352to side plate 354. In one embodiment, their longitudinal axes (that is,their axes transverse to the path of travel of expiring web 314) arenot, however, perpendicular to the path of travel of expiring web 314through web splicer 310. Rather, these longitudinal axes are offset asmall amount, for example, five degrees, from the perpendicular so thatthe splice, when formed, will be offset from the side edges of thejoined webs.

Nip assembly 362 is best shown in FIGS. 10 and 15 and includes a pair ofend plates 372. End plates 372 are mounted opposite each other on theinside facing surfaces of side plates 352 and 354. They are connected at374 to the side plates and are adapted to be pivoted, in a planeparallel to the side plates, about their aligned points of connections374. A nip bar 376 is connected with one end of each of plates 372. Apair of conventional pneumatic cylinders 378 is connected, at theircylinder ends, to the inside surface of side plates 352 and 354. The rodends of these cylinders 378 are connected with the other ends of theplates 372. Actuation of cylinders 378 causes end plates 372 to pivotabout their points of connection 374 and to bring the inner end of nipbar 376 into and out of engagement with the periphery of idler roll 332.When cylinders 378 urge nip bar 376 into engagement with idler roll 332,expiring web 314 will be clamped between the inner end of bar 376 andidler roll 332.

Referring to FIGS. 10, 11, 15, and 17, new web preparation assembly 364is supported, at each end, by generally “L” shaped brackets 382. Thesebrackets are, in turn, mounted on the upper ends of side plates 352 and354 adjacent to the exit end of web splicer 310. Each bracket 382includes a horizontally disposed guide rod 384. Rods 384 are supportedat their upstream or forward ends by upstanding members 386 mounted onthe brackets. Coaxially aligned, inwardly directed, facing locating pins388 are secured to the sides of the upper ends of members 386. Thedownstream or rearward ends of rods 384 are supported by members 392that are, in turn, secured to brackets 382.

A carrier block 394 is mounted on each rod 384. These carrier blocks 394are adapted to be slid along the lengths of rods 384 between members 386and 392. Each block 394 includes a upwardly directed, inwardly facingmounting plate 396. A guide rod 398 extends across web splicer 310. Itsends are secured adjacent to the upper, downstream corner of thesemounting plates 396. An anvil member 402 extends between mounting plates396 and is secured, at each end, to the lower, upstream corners of theseplates 396. Rod 398 and member 402 move with plates 396 when carrierblocks 394 are slid along rods 384.

A cutting element 404 is mounted along the upstream or forward edge ofanvil member 402. The upper, upstream corner edge of element 404 issharpened and serves as a cutting edge along which new web 324 may becut or trimmed. The length of the cutting element is slightly longerthan the width of expiring web 314 and new web 324. The downstream endof a shield 406 is supported below and carried by the central portion ofanvil member 402. The upstream end of shield 406 is bent upwardly sothat its distal end is substantially in the same plane as cuttingelement 404 although it is spaced upstream from that element. The widthof shield 406 is less than the width of expiring web 314 and new web324.

Coil extension springs 408 are connected between the downstream ends ofbrackets 382, beneath member 392, and anvil member 402. These springs408 are stretched, as shown in FIG. 17, when assembly 364 is moved toits upstream or first position. They thus urge assembly 364 to return toits downstream or second position shown in FIG. 16. A pair of pivotableplates 412 are mounted, adjacent to their upper, downstream corners, onrod 398. The plates are disposed close to plates 396. A nip bar 414extends between plates 412 and its ends are secured to the platesadjacent to their upstream, lower corners. Plates 412 are sized suchthat the lower edge surface of nip bar 414 may engage the upper surfaceof anvil member 402 as described herein.

A trimmer subassembly 416 is also mounted on rod 398 between the plates412. Subassembly 416 includes a carrier block 418 that may be slid alongrod 398 in a direction parallel to the longitudinal axis of the rod.Carrier block 418 may also be pivoted about the longitudinal axis of rod398. A handle 422 is secured to the upper surface of carrier block 418to facilitate the sliding and pivotal movement of subassembly 416.

A member 424 is secured to the upstream facing surface of carrier block418. A knife wheel 426 is mounted on the upstream facing side of member424 adjacent to the lower end of member 424. Wheel 426 is adapted torotate about its central axis that is substantially perpendicular to theupstream facing surface of member 424 and thus of carrier block 418. Adownstream peripheral edge of wheel 426 is beveled and sharpened so asto form a sharp cutting edge. Wheel 426 is positioned so that itssharpened downstream edge can cooperate with the upstream cutting edgeof element 404 as described herein.

A downstream facing roller bearing 428 is mounted on the downstreamfacing side of member 424. Its axis of rotation is parallel with theaxis of rotation of wheel 426. Bearing 428 is positioned so that it mayride along the upper surface of nip bar 414. Bearing 428 facilitates thesliding of carrier block 418 along rod 398. A pair of pin latchingmembers 432 are secured to the upstream, inside upper corners of pivotalplates 412. The upstream ends of pin latching members 432 projectupstream beyond the upstream ends of plates 412. Notches are formed inthese upstream ends of pin latching members 432 and are sized so thatadjacent locating pins 388 may be received within the notches.

As noted, assembly 364 is adapted to be moved between a first orupstream position, such as shown in FIG. 17, and a second or downstreamposition, such as shown in FIG. 16. When preparing the leading portionof new web 324 from for a splice, new web 324 is led around idler roller358 and to and over anvil plate 402. The operator then grasps handle 422and slides assembly 364, along rods 384, to its first position. Stillusing handle 422, subassembly 416 is then rotated counterclockwise aboutthe longitudinal axis of rod 398 to its “down” or cutting position asshown in FIG. 17. In this cutting position, the notches in members 432fit over locating pins 388. Locating pins 388 are set so that when thisoccurs, the sharpened beveled edge of wheel 426 is adjacent to and incooperative engagement with the upstream cutting edge of cutting element404. Similarly, when subassembly 416 is pivoted to its cutting position,the lower surface of nip bar 414 clamps the adjacent, underlying portionof new web 324 against the upper surface of anvil member 402. Theoperator thereafter slides handle 422, and thus with entire trimmersubassembly 416, along rod 398 while continuing to hold subassembly 416in its cutting position. This sliding movement of subassembly 416results in new web 324 being cut by the rotation of knife wheel 426along the upstream edge of cutting element 404. Hence, the resultingleading end of new web 324 is aligned with and congruent to the upstreamedge of cutting element 404. Because of the cooperation between locatingpins 388 and the notches in members 432, the cutting edge of element 404is always precisely located (that is, in the same vertical plane)vis-a-vis assemblies 366 and 368, when assembly 364 is in its firstposition. This assures that the leading end of each new web, like newweb 324, will be located in the same vertical plane after being cut ortrimmed by web preparation assembly 364.

Assembly 364 may be moved to its second or downstream position by theoperator pivoting handle 412, and thus trimmer subassembly 416 in aclockwise direction to its “up” or non-cutting position. This raises thenotches in members 432 off pins 388. The operator, assisted by springs408, will thereafter return assembly 364 to its second position. Springs408 serve to retain assembly 364 in that position. Again referring toFIGS. 10, 11, and 15-19, new web holding assembly 366 includes first andsecond vacuum bars or tubes 434 and 436 having generally rectangularcross-sections. The longitudinal axes of tubes 434 and 436 are parallel.Bar 434 extends across web splicer 310. Annular collar members 440 areformed on the ends of tube 434 and are adapted to slidingly receive theupper ends of vertical guide posts 442. The lower ends of guide posts442 are secured to members 444 that, in turn, are secured to side plates352 and 354.

Conventional pneumatic cylinders 446 are secured to the outside surfaceof plates 464 adjacent to posts 442. More specifically, the cylinderends of cylinders 446 are secured to the plates while their rod ends areconnected, through blocks 448, with annular collar members 440.Actuation of cylinders 446 results in the movement of vacuum bar 434 upand down along posts 442. Vacuum bar 436 is shorter in length thanvacuum bar 434. Its ends are journaled for pivotal movement in blocks452 that are secured to the downstream facing side of vacuum bar 434. Apair of flanges are integrally formed on the upwardly facing side, asshown in FIG. 15, of vacuum bar 436 adjacent to blocks 452. A pair ofsupport towers 456 are secured, at their lower ends, to the uppersurface of vacuum bar 434 intermediate its ends. These towers projectupwardly above vacuum bars 434 and 436.

Conventional pneumatic cylinders 458 are connected, at their cylinderends, with the upper ends of these support towers. The rod ends ofcylinders 458 are connected, by pins, with flanges 454. Actuation ofcylinders 458 causes vacuum bar 436 to pivot, through an arc of 90°,from a first position, as shown in FIG. 15, to a second position, asshown in FIGS. 18 and 19. The interiors of vacuum bars 434 and 436 areconnected with a conventional vacuum pump, not shown, by conventionaltubing, also not shown. Operation of the vacuum pump causes a “vacuum”to be drawn within the interior of these vacuum bars.

The downwardly facing or lower surface of vacuum bar 434 includes aplurality of small holes in the area adapted to overlie the webs runningthrough web splicer 310. A layer of resilient material, such as rubber,is secured to the lower surface of vacuum bar 434. This resilient layerincludes similar small holes which coincide with the holes in the lowersurface of vacuum bar 434 so that these holes permit air communicationbetween an interior and an exterior of vacuum bar 434. When a portion ofnew web 324 is brought into surface to surface contact with the lowersurface of vacuum bar 434, the vacuum within vacuum bar 434 issufficient to hold the portion of new web 324 tightly against the lowersurface. Similarly, vacuum bar 436 includes a surface 462 that facesdownstream when the bar is in its first position and faces downwardlywhen the bar is in its second position. Vacuum bar 434 is constructed sothat when it is in its second position, the vertical plane, thatincludes the cutting edge of element 404 when web preparation assembly364 is in its first position, bisects surface 462 so as to dividesurface 462 into a downstream half and an upstream half.

Surface 462 has a plurality of small holes therein that permit aircommunication between the interior and exterior of the vacuum bar. Theholes are in the area adapted to overlie expiring web 314 and new web324 when vacuum bar 436 is in its second position. A layer of resilientmaterial, such as rubber, is also secured to surface 462. Holes in theresilient layer are aligned with the holes in surface 462 so that thevacuum within vacuum bar 436 may communicate with the exterior of vacuumbar 436.

When expiring web 314 is running and before a splice is initiated,assembly 366 is normally in its upper position with vacuum bar 436rotated to its first position, as shown in FIG. 15. When in thisposition, the lower surface of vacuum bar 434 is approximately 1¾ inchesabove expiring web 314 as it runs through web splicer 310. When assembly366 is moved to its lower position during the course of a splice (andvacuum bar 436 is rotated to its second position as shown in FIG. 19),the lower surface of tube 436 and surface 462 lie in a common,horizontal plane which may be approximately 3/16 of an inch aboveexpiring web 314.

Web cutting assembly 368 is best illustrated in FIGS. 12-14, andincludes a pair of brackets 464 secured to the outside surfaces of sideplates 352 and 354. A pair of rods 466 extend between these brackets 464and have their ends secured to them. The longitudinal axes of rods 466are parallel to the longitudinal axes of vacuum bars 434 and 436. Rods466 are spaced well below the path of travel of expiring web 314.

A wheel and knife carrier subassembly 468 is mounted on rods 466 and isadapted to slide along the rods. Before a splice is initiated, thissubassembly is positioned adjacent to side plate 352 as shown in FIG.12. A block 472 depends from the lower surface of subassembly 468. Thelower end of block 472 is connected with the opposite ends of aconventional cable cylinder 474 by means of a U-shaped member 476. Cablecylinder 474 includes cables that are connected with member 476 andextend around guide rollers 478 mounted at opposite ends of cylinder482. The other ends of the cables are connected with a piston, notshown, positioned and slidable within cylinder 482. An example of such acable cylinder is the Model No. S100-3/4-AT cylinder manufactured byTol-O-Matic, Inc., of Minneapolis, Minn.

When cable cylinder 482 is actuated, the piston within cylinder 482fires. This causes subassembly 468 to be moved, at a high velocity,along rods 466 and across the adjacent path of travel of expiring web314. As best seen in FIGS. 13 and 14, wheel and knife carriersubassembly 468 includes a first, vertically disposed plate 484. Theupstream facing surface of plate 484 is parallel with the longitudinalaxis of rods 466. Before a splice is initiated, inwardly facing end 486of plate 484 is disposed adjacent to the side edge of expiring web 314as that web moves through web splicer 310.

A first wheel 488 is mounted on the upstream facing surface of plate 484adjacent to its upper inner corner. First wheel 488 has an annularperipheral surface 489 having a width, in a direction parallel to itsaxis of rotation, substantially equal to one-half of the width ofsurface 462. First wheel 488 is adapted to rotate about an axis ofrotation which is perpendicular to the plane of the upstream facingsurface of plate 484. The upstream side, annular peripheral edge 490 ofsurface 489 of first wheel 488 is beveled and sharpened so that thisannular edge serves as a rotatable knife blade. The upper portion ofannular peripheral surface 489 projects slightly above the plane of theupper surface 492 of the plate. A generally “J” shaped knife member 494is mounted on upper surface 492 of plate 484. More specifically, shorterleg 496 of “J” shaped member 494 is secured, as for example, by bolts,at the inner corner of surface 492. Longer leg 498 of member 494 has adownstream edge that is disposed closely adjacent to edge 490 of firstwheel 488. The distal end of longer leg 498 projects inwardly beyond theinnermost extending annular peripheral surface of wheel 488 and has aleading, chiseled edge. The distal end of leg 498 is adapted to extendbetween expiring web 314 and new web 324 even after assembly 366 hasbeen moved down to its lower position.

When a splice is to be made and expiring web 314 is to be cut (that is,when subassembly 468 is to be moved rapidly across the web), the upperportion of peripheral surface 489 of first wheel 488 initially engagesthe adjacent end of surface 462 of vacuum bar 436. First wheel 488 isaligned so that its peripheral surface 489 only engages the downstreamhalf of surface 462. This engagement causes the wheel to rotate in aclockwise direction as seen in FIGS. 12 and 13. As subassembly 468 andthus wheel 488 continue to move along rod 466, expiring web 314,starting with its adjacent side edge, contacts peripheral surface 489 ofthe rotating wheel and is cut or sheared, at a moving point of cuttingdefined by the cooperation between beveled edge 490 of wheel 488 and theadjacent part of the downstream facing edge of leg 498. The cut part ofthe trailing or downstream end of expiring web 314 (that is, the partimmediately behind the moving point of cutting) moves up and over theupper portion of peripheral surface 489 of wheel 488. The cut part ofupstream end of expiring web 4 drops down, by gravity, below subassembly468 and out of the open bottom of web splicer 310. The high velocitymovement of subassembly 468 across expiring web 314 rapidly cuts theweb, a part at a time, from one side edge to the other.

A second, smaller plate 502 is mounted on the upstream side of plate 484to the outside of second wheel 488. A second wheel 504 is mounted on theupstream side of this second plate. Second wheel 504 is mounted forrotation about an axis parallel to but spaced outwardly from the axis ofrotation of wheel 488. Like first wheel 488, second wheel 504 has anannular peripheral surface 505 that has a width, in the directionparallel to its axis of rotation, substantially equal to one-half of thewidth of surface 462. Second wheel 504 is aligned so that its peripheralsurface 505 only engages the upstream half of surface 462. Also likefirst wheel 488, the upper portion of the annular peripheral surface ofsecond wheel 504 projects above upper edge surface 492 of plate 486. Acoil compression spring 506 biases plate 502 and thus second wheel 504upwardly. A set screw 508 is adapted to adjust the tension on spring 506so that the upper portion of peripheral surface 505 of second wheel 504is slightly higher than the upper portion of peripheral surface 489 offirst wheel 488.

As noted, second wheel 504 is aligned so that its upper portion of itsperipheral surface 505 will engage the upstream half of surface 462 ofvacuum bar 436 when assembly 366 is in its lower position as shown inFIG. 19 and when the subassembly 468 moves across the path of travel ofexpiring web 314. When second wheel 504 first engages surface 462,second wheel 504 is forced slightly downwardly against the bias ofspring 506. This causes second wheel 504 to exert a stronger line ofpressure on surface 462 second wheel 504 moves across vacuum bar 436.

Web splicer 310 is configured to form a butt splice to join a leadingedge of a new web to a trailing edge of an expiring web that is beingfed to a continuous web processing operation using a suitable linearprocess, such as described above with reference to FIGS. 5 and 6, or asuitable monolithic process, such as described above with reference toFIGS. 7 and 8. In certain embodiments, the methods described herein mayinclude a linear process or a monolithic process for forming the buttsplice using an UV-curable liquid adhesive applied within a gap formedbetween the leading edge of the new web and the trailing edge of theexpiring web, as described in detail above.

In one embodiment, as expiring web 314 runs through web splicer 310, nipassembly 362 is not actuated. New web preparation assembly 364 is in itssecond or downstream position, as shown in FIGS. 10 and 16, new webholding assembly 366 is in its upper position as shown in FIGS. 16 and17, and wheel and knife carrier subassembly 468 is positioned adjacentto side plate 352. The operator feeds in the leading portion part of newweb 324 around idler roll 358, past assembly 366 and back between theupper surface of anvil member 402 and the lower surface of nip bar 414of assembly 364. The end of new web 324 may be easily threaded betweenanvil 402 and nip bar 414 because trimmer subassembly 416 is in itsnon-cutting position, as shown in FIGS. 10 and 18, due to coil extensionsprings, not shown, which biases it to that position. The operator thengenerally aligns the side edges of new web 324 with the side edges ofrunning expiring web 314.

The operator next grasps handle 422 and moves assembly 364 forwardtoward its first or upstream position. When that position is reached,the operator moves handle 422 upwardly. This pivots trimmer subassembly416 counterclockwise, about the axis of rod 398, to its cutting positionand so as to hook the notches in plates 432 over locating pins 388. Therotation of trimmer subassembly 416 causes the bottom of nip bar 414 toclamp new web 324 against anvil member 402. The upstream movement ofassembly 364 has additionally caused shield 406 to engage the undersideof new web 324 and press a portion of new web 324 upwardly against thelower surface of vacuum bar 434. The vacuum in that bar thereafter holdsthis portion of new web 324 tightly against the lower surface.

The operator next slides trimmer subassembly 416 along rod 398 from oneside to the other. This causes wheel 426 to move along the cutting edgeof element 404. The relative movement between the cutting edge of wheel426 and element 404 results in new web 324 being trimmed or cut. Asnoted, this trimmed leading end of new web 324 is aligned with andcongruent with the cutting edge of element 404. The trimmed leading endof new web 324 is also spaced preselected distance downstream from theportion of new web 324 held by vacuum bar 434 due to the cooperationbetween pins 388 and the notches in plates 432. During this trimming ofthe leading end of new web 324, vacuum bar 436 remains in its first orupper position. After the leading end of new web 324 has been trimmed,assembly 364 is returned to its second or downstream position. This isdone by the operator pivoting handle 422 in a clockwise direction sothat the notches in plates 432 lift off locating pins 388. Assembly 364then moves to its second position under the bias of springs 408. When inits second position, assembly 346 is relatively remote from assemblies366 and 368 and does not interfere with the subsequent steps in thesplicing operation.

When a splice is to be initiated, the movement of expiring web 314through web splicer 310 is brought to a stop by actuating the brakes forexpiring web 314 and new web 324. The application of these brakes haltsthe movement of the portion of expiring web 314 in web splicer 310.Nevertheless expiring web 314, downstream from festoon 338, continues torun, without any loss of speed or tension, to the web utilizationapparatus. After the portion of expiring web 314 in web splicer 310 isstopped, its lack of movement is sensed by conventional sensors, notshown, that may then initiate the splicing operation. Alternatively, thesplicing operation may be initiated manually by the operator.

At the start of the splicing operation, cylinders 378 are actuated sothat nip bar 376 clamps expiring web 314 against roll 332. Expiring web314 is thus held under tension between idler roll 332 and expiring web314. At the same time, cylinders 458 and 446 are actuated. This causesbar 436 to be rotated to its second or down position, and bars 434 and436, and thus new web 426, to be moved downwardly to its lower position.Cable cylinder 474 is then fired resulting in wheel and knife carriersubassembly 468 being rapidly moved across expiring web 314 from one ofits side edges to the other. With new web 324 moved into close proximitywith expiring web 314, the distal end of leg 498 of member 494 projectsbetween the webs to assure that the webs remain separate as subassembly468 moves across expiring web 314.

Subassembly 468 is positioned, vis-a-vis vacuum bar 436, so that theupper portions of peripheral surfaces 489 and 505 of wheels 488 and 504come into contact with surface 462 of bar 436 just prior to the timethat wheel 488 and knife member 494 first contact the side edge ofexpiring web 314. Due to this initial contact with surface 462, bothwheels 488 and 504 are already rotating, in a clockwise direction, bythe time there first is contact between expiring web 314 and wheel 488and knife member 494. As noted above, expiring web 314 is cut or shearedat the point where expiring web 314 contacts sharpened, beveled edge 490of wheel 488 and the adjacent part of leg 498 of knife member 494. As aresult, the point of cutting of expiring web 314 moves across the web,from one side edge to the other, as subassembly 468 moves across theweb. The uncut part of expiring web 314 (that is, the part ahead ofsubassembly 468) remains under tension. The cut part of expiring web314, immediately downstream from this point of cutting, rides up andover the upper portion of peripheral surface 489 of wheel 488.

In one embodiment, a butt splice is formed to join together the leadingedge of new web 324 and the trailing edge of expiring web 314, asexpiring web 314 runs downstream under tension along a predeterminedpath of travel. With both new web 324 and expiring web 314 secured, thetrailing edge of expiring web 314 is registered with the leading edge ofnew web 324 to define a gap therebetween along a width of new web 324and a width of expiring web 314. In one embodiment, the gap is notgreater than 1 millimeter (mm); however, in alternative embodiments thegap may exceed 1 mm. With each of the leading edge and the trailing edgesecured by an associated nip, for example, an adhesive applicatordispenses a controllable amount of UV-curable liquid adhesive within thegap. In certain embodiments, the adhesive applicator includes a needleapplicator to facilitate accurately dispensing a desired quantity ofliquid adhesive in a desired area within the gap. The adhesiveapplicator can be controlled using a suitable controller (not shown) todispense a precise quantity of adhesive as the adhesive applicator movesalong a length of the gap between a first lateral edge of expiring web314 and an opposing second lateral edge of expiring web 314. A curingdevice is operatively coupled to the adhesive applicator such that thecuring device follows the adhesive applicator along the gap to cure theadhesive dispensed in the gap. In one embodiment, the curing deviceincludes one or more ultraviolet (UV) light sources, such as lightemitting diodes (LEDs), configured to emit UV light at a suitableintensity to cure the adhesive within a desired time. In a particularembodiment, the light sources are offset with respect to a z-axis normalto a longitudinal axis to allow for better visibility of the gap and theadhesive and/or to accommodate off-gassing during the curing process,for example. In an alternative embodiment, the curing device includesone or more light sources that are fixed or stationary with respect toexpiring web 314 and directed onto an area in which the adhesive isdispensed or applied such that after the adhesive applicator movesacross the gap, the light sources are activated to emit UV light at asuitable intensity to cure the adhesive within a desired time. Forexample, a wattage output of each light source within the curing deviceis controllable to emit UV light at an intensity suitable to cure theadhesive within a set time. In certain embodiments, the light sourcesare controlled by a timer or other suitable controller (not shown) suchthat the light sources are activated to emit light only during thecuring process. Once the adhesive is cured, a sufficiently strong buttsplice is formed to join new web 324 to expiring web 314.

As soon as subassembly 468 completes its travel across expiring web 314(that is, as soon as the leading edge of new web 324 is joined to thetrailing edge of expiring web 314), the brakes for expiring web 314 andnew web 324 are released, and cylinder 378 in the nip assembly is againactuated so that nip bar 376 is moved away from the periphery of idlerroller 332. At the same time, cylinders 446 are actuated so as to moveassembly 366 upwardly to its upper or first position. At this same time,the vacuum in bars 434 and 436 may be reduced or momentarily eliminated.The newly spliced web immediately begins to accelerate under the forceof expiring web 314 being pulled through festoon 338. Thereafter,expiring web 314 is replaced by another new roll and new roll 324 isrotated to the position occupied by expiring web 314 as shown in FIG. 9.Before this occurs (that is, while running expiring web 324 is stillpassing around idler roll 358), subassembly 468 will return to itsoriginal position, adjacent side plate 352, so as to avoid anypossibility that subassembly 468 might contact running new web 324.Preparation for another splice may then commence.

FIGS. 20A-23B illustrate several non-limiting examples of a butt spliceformed in accordance with the embodiments as described herein andillustrating a front surface of the spliced webs facing the splicingassembly during the splicing process (FIGS. 20A, 21A, 22A, and 23A) anda respective opposing back surface of the spliced webs contacting asupport surface of the anvil during the splicing process (FIGS. 20B,21B, 22B, and 23B).

Several embodiments of a method are provided for forming a butt spliceto join together the leading edge of a web from a new roll of material,or a new web, to the trailing edge of a web from an expiring roll ofmaterial, or an expiring web, as the expiring web runs downstream undertension along a predetermined path of travel. The butt splice is formedwithout any material overlap and without slowing or stopping the web-fedprocess, and has a strength sufficient to join the new web to theexpiring web and withstand stresses and tension exerted thereon duringthe downstream web processing. Moreover, the embodiments allow for oneor more of the following: adjusting or controlling a size of the gapdefined between the new web and the expiring web, aligning andregistering the leading edge of the new roll with the trailing edge ofthe expiring web, forming the boundaries or boarders of the butt splice,reducing or eliminating web registration errors, and reducing oreliminating undesirable adhesive leakage through the gap.

As the expiring web is unwound from the expiring roll of material, thenew web is prepared and immobilized for splicing to the trailing edge ofthe expiring roll. The new web is cut or trimmed to form a leading edge.In one embodiment, the new web is cut or trimmed in a lateral directionfrom a first lateral side to an opposing second lateral side of the newweb along a line substantially perpendicular to the lateral sides and alongitudinal axis of the new web. In an alternative embodiment, the newweb is cut or spliced in the lateral direction along a line that isnon-perpendicular to the longitudinal axis of the new web, for exampleextending along a line at an angle of ±5°-15° with respect to thelongitudinal axis, to reduce the risk of a secondary operation impactingthe splice across the full width. Similarly, as the expiring web isunwound from the expiring roll, the expiring web is cut or trimmed toform the trailing edge of the web.

In one embodiment, a splicing assembly, such as a shearing wheel or ashearing blade, is utilized for cutting the webs to form the respectiveleading and trailing edges. For example, in a particular embodiment, asdescribed herein in reference to FIGS. 1-6, and particularly inreference to FIGS. 5 and 6, during a dynamic, linear process a shearingwheel is moved across a width of the web defined substantiallyperpendicular to a longitudinal axis of the web, to cut or splice theweb. The shearing wheel may move along the width of the web along a linesubstantially perpendicular to a longitudinal axis of the web,transversally across a width of the web, or along a line at anon-perpendicular angle with respect to the longitudinal axis of theweb. In an alternative embodiment, as described below in reference toFIGS. 1-4, 7, and 8, and particularly in reference to FIGS. 7 and 8,during a monolithic process a splicing assembly including a shearingblade is lowered onto the web to cut or splice the web. In thisembodiment, the shearing blade has a length greater than the width ofthe web to ensure the web is entirely cut or spliced. The shearing blademay be positioned along the width of the web along a line substantiallyperpendicular to a longitudinal axis of the web, transversally across awidth of the web, or along a line at a non-perpendicular angle withrespect to the longitudinal axis of the web to provide an increasedsurface area to facilitate joining or splicing the webs.

The trailing edge of the expiring web is positioned with respect to theleading edge of the new roll to define a gap therebetween. In oneembodiment, the new web is immobilized at or near the leading edge andthe expiring web is immobilized at or near the trailing edge before orafter the respective webs are cut or trimmed. In a particularembodiment, the webs are immobilized using a suitable clamp or nip tosecure the webs against a support surface, such as the anvil, after thetrailing edge is positioned with respect to the leading edge to definethe gap.

A curable liquid adhesive, such as a suitable UV-curable liquidadhesive, is dispensed or applied within the gap between the trailingedge and the leading edge. In certain embodiments, the curable liquidadhesive is dispensed from a tube or container using a needle applicatorconfigured to dispense the liquid adhesive at a controlled rate. Theneedle applicator can be adjusted to adjust an amount of liquid adhesivedispensed or applied within the gap, based at least in part on the typeof materials forming the webs and properties of the materials, forexample, porous nonwoven webs, non-porous paper, fiberglass, or films.The amount of adhesive dispensed, as well as the dispense time, can beadjusted and controlled to facilitate decreasing or preventing undesiredoversaturation of the webs with adhesive and reducing or eliminatingadhesive leakage through the gap.

After a suitable time to allow for adhesive diffusion or wicking, ifdesired, the liquid adhesive is cured to form the butt splice to couplethe new web of material to the expiring web of material. In certainembodiments utilizing a UV-curable liquid adhesive, one or more UV lightsources, such as one or more UV-curing light emitting diodes (LEDs),emit a light having a controllable UV-curing intensity to cure theliquid adhesive in a suitable time period. In certain embodiments, theone or more light sources are positioned substantially perpendicular toa surface of the web. Alternatively, the one or more light sources maybe offset with respect to a z-axis of the surface of the web, i.e., at anon-perpendicular angle with respect to the surface of the web, to allowfor better visibility of the gap and dispensed adhesive and/or toaccommodate off-gassing during the curing process, for example. Further,in one embodiment, the one or more light sources are operatively coupledto the splicing assembly such that the light sources move with thesplicing assembly, as described herein. For example, in a particularembodiment one or more light sources are moved along a length of the gapto emit a UV light to cure the liquid adhesive. Alternatively, the lightsources can be fixed or stationary with respect to the anvil anddirected onto an area of the gap in which the curable liquid adhesive isdispensed or applied to cure the adhesive. Additionally, the lightsources may be controlled by a timer or other suitable controller suchthat the light sources emit UV-curing light only during the curingprocess.

Referring further to FIGS. 5 and 6, in one embodiment, a method isdisclosed for forming a butt splice to join together the leading edge ofthe new web and the trailing edge of the expiring web, as the expiringweb runs downstream under tension along a predetermined path of travel.As shown in FIGS. 5 and 6, a leading edge 102 is formed on a new web ofmaterial 104 by trimming or cutting the new web 104. Once new web 104 istrimmed or cut, new web 104 is temporarily secured against a surface ofan anvil 106 using nip 40 or a clamp to facilitate joining new web 104to an expiring web 110. With leading edge 102 secured against anvil 106,expiring web 110 is temporarily secured against anvil 30 using nip 41 ora clamp. With both new web 104 and expiring web 110 secured to anvil 30,splicing assembly 135 is moved laterally across a width of expiring web110. Splicing assembly 135 includes a shear wheel 116, an adhesiveapplicator 118, and a curing device 120 including one or more UV-curinglight sources. As splicing assembly 135 moves across expiring web 110,shear wheel 116 cuts or trims expiring web 110 to form a trailing edge122. Trailing edge 122 is registered with leading edge 102 to define agap 124 between leading edge 102 and trailing edge 122 along a width ofnew web 104 and a width of expiring web 110. With each of leading edge102 and trailing edge 122 secured to anvil 30, adhesive applicator 118dispenses a controllable amount of UV-curable, liquid adhesive 126within gap 124. In certain embodiments, adhesive applicator 118 includesa needle applicator to facilitate accurately dispensing a desiredquantity of liquid adhesive in a desired area within gap 124. As shownin FIG. 5, adhesive applicator 118 is operatively coupled to shear wheel116 such that adhesive applicator 118 moves across expiring web 110 withshear wheel 116. Adhesive applicator 118 is controlled using a suitablecontroller to dispense a precise quantity of adhesive as adhesiveapplicator 118 moves along a length of gap 124 between a first lateraledge 128 of expiring web 110, substantially parallel to a longitudinalaxis 130 of expiring web 110, and an opposing second lateral edge 132 ofexpiring web 110, as shown in FIG. 5.

Curing device 120 is operatively coupled to adhesive applicator 118 suchthat curing device 120 follows adhesive applicator 118 along gap 124 tocure adhesive 126 dispensed in gap 124. In one embodiment, curing device120 includes one or more ultraviolet (UV) light sources 134 as shown inFIG. 6, such as LEDs, configured to emit UV light at a suitableintensity to cure adhesive 126 within a desired time. In a particularembodiment, light sources 134 are offset with respect to a z-axis 134normal to longitudinal axis 128, as shown in FIG. 6, to allow for bettervisibility of gap 124 and adhesive 126 and/or to accommodate off-gassingduring the curing process, for example. In an alternative embodiment,curing device 120 includes one or more light sources 134 that are fixedor stationary with respect to expiring web 110 and directed onto an areain which adhesive 126 is dispensed or applied such that after adhesiveapplicator 118 moves across gap 124, light sources 134 are activated toemit UV light at a suitable intensity to cure adhesive 126 within adesired time. For example, a wattage output of each light source 134within curing device 120 is controllable to emit UV light at anintensity suitable to cure adhesive 126 within a set time. In thisembodiment, light sources 134 may also be controlled by a timer or othersuitable controller such that light sources 134 are activated to emitlight only during the curing process. Once adhesive 126 is cured, astrong butt splice 140 is formed, as shown in FIG. 6, to join new web104 to expiring web 110. Nips 40, 41 are then released to allow thejoined webs to move downstream.

Referring further to FIGS. 7 and 8, in an alternative embodiment, amethod is disclosed for forming a butt splice to join the leading edgeof the new web to the trailing edge of the expiring web, as the expiringweb runs downstream under tension along a predetermined path of travel.As shown in FIGS. 7 and 8, leading edge 102 is formed on new web ofmaterial 104 by cutting or trimming new web 104. Once new web 104 is cutor trimmed, new web 104 is temporarily secured against anvil 30 by nip40 or a clamp, as shown in FIG. 8, to facilitate joining new web 104 toexpiring web 110. With leading edge 102 secured against anvil 30, in oneembodiment, expiring web 110 is temporarily secured against anvil 30 bynip 41 or a clamp 212. With both new web 104 and expiring web 110secured to anvil 30, a splicing assembly 235 is moved, such as by avertical gravity drop, towards a surface of expiring web 110 registeredwith new web 104. Splicing assembly 235 includes a shear blade 216 andan adhesive applicator manifold 218. In one embodiment, a curing device220, including one or more UV-curing light sources 222 as shown in FIG.8, is positioned with respect to a support surface of anvil 30 on whicheach of new web 104 at leading edge 102 and expiring web 110 at trailingedge 122 is supported. As splicing assembly 235 moves through expiringweb 110, shear blade 216 cuts or trims expiring web 110 to form trailingedge 122. Trailing edge 122 is registered with leading edge 102 todefine gap 124 between leading edge 102 and trailing edge 122 along awidth of new web 104 and a width of expiring web 110.

As shearing blade 216 passes through expiring web 110, one or more stops224, shown in FIG. 7, are positioned under anvil 30 to stop or preventfurther movement of shearing blade 216 and facilitate accuratelypositioning adhesive applicator manifold 218 over gap 124 definedbetween leading edge 102 and trailing edge 122. With each of leadingedge 102 and trailing edge 122 immobilized, adhesive applicator manifold218 dispenses a controllable amount of UV-curable, liquid adhesive 126within gap 124. In certain embodiments, adhesive applicator manifold 218includes one or more needle applicators to facilitate accuratelydispensing a desired quantity of liquid adhesive in a desired areawithin gap 124. Adhesive applicator manifold 218 is controlled using asuitable controller (not shown) to dispense a precise quantity ofadhesive as adhesive applicator manifold 218 is positioned over a lengthof gap 124 between a first lateral edge 128 of expiring web 110 andsecond lateral edge 132 of expiring web 110.

As shown in FIG. 8, curing device 220 includes one or more UV-curinglight sources 222 positioned on opposing lateral sides of gap 124. Inthis embodiment, each light source 222 is fixed or stationary withrespect to expiring web 110 and directed onto an area in which adhesive126 is dispensed or applied such that after adhesive applicator manifold218 dispenses adhesive 126 and is retracted upward to an initialposition, light sources 222 are activated to emit UV light at a suitableintensity to cure adhesive 126 within a desired time. For example, awattage output of each light source 222 within curing device 220 iscontrollable to emit UV light at an intensity suitable to cure adhesive126 within a set time. In this embodiment, light sources 222 may also becontrolled by a timer or other suitable controller such that lightsources 222 are activated to emit light only during the curing process.In one embodiment, curing device 220 includes one or more UV lightsources 222 as shown in FIG. 8, such as LEDs, configured to emit UVlight at a suitable intensity to cure adhesive 126 within a desiredtime. In a particular embodiment, light sources 222 are offset withrespect to z-axis 134 normal to longitudinal axis 128, as shown in FIG.8, to allow for better visibility of gap 124 and adhesive 126 and/or toaccommodate off-gassing during the curing process, for example. Inalternative embodiments, curing device 220 is operatively coupled tosplicing assembly 235 such that curing device 220 follows adhesiveapplicator manifold 218 towards gap 124 to cure adhesive 126 dispensedin gap 124.

Once adhesive 126 is cured, a sufficiently strong butt splice 140 isformed to join new web 104 to expiring web 110. Nips 40, 41 are thenreleased to allow the joined webs to move downstream.

The described apparatus and methods are not limited to the specificembodiments described herein. In addition, components of each apparatusand/or steps of each method may be practiced independently andseparately from other components and method steps, respectively,described herein. Each component and method also can be used incombination with other systems, apparatus, and methods.

This written description uses examples to disclose the embodiments,including the best mode, and also to enable any person skilled in theart to practice the embodiments, including making and using any devicesor systems and performing any incorporated methods.

What is claimed is:
 1. A method for forming a butt splice to join afirst web of material to a second web of material, comprising: cutting afirst web of material to form a first edge; cutting a second web ofmaterial to form a second edge, the cutting being performed by acutting, adhesive applying and curing apparatus, the second edgepositioned with respect to and registered with the first edge to definea gap between the first edge and the second edge; applying a curableadhesive within the gap, the applying the curable adhesive beingperformed by the cutting, adhesive applying and curing apparatus, thecurable adhesive being applied only within the gap so as to provide asplice having a same thickness as each of the first and second webs; andcuring the curable adhesive to form a butt splice that joins the firstweb of material to the second web of material, the curing beingperformed by the cutting, adhesive applying and curing apparatus.
 2. Themethod of claim 1, wherein the curable adhesive is a curable liquidadhesive.
 3. The method of claim 1, wherein the curable adhesive is aUV-curable adhesive.
 4. The method of claim 3, wherein the UV-curableadhesive is cured using one or more UV light sources.
 5. The method ofclaim 1, wherein the material of the first web and the material of thesecond web is selected from the group of material consisting of film,coated film or material, fiber, fiberglass, paper including cardboard,nonwoven web, woven web, and combinations thereof.
 6. The method ofclaim 1, further comprising: processing the web in a continuous webprocessing operation; and temporarily immobilizing a portion of thefirst web of material and a portion of the second web of material duringthe cutting of the second web and during the applying of the curableadhesive and during the curing of the curable adhesive.
 7. The method ofclaim 1, wherein the cutting of the first web of material and thecutting of the second web of material includes cutting the webs in alateral direction from a first lateral side to an opposing secondlateral side of the respective first and second webs along a linesubstantially perpendicular to the lateral sides and a longitudinal axisof the respective first and second webs.
 8. The method of claim 1,wherein the second web of material is cut in the lateral direction alonga line that is non-perpendicular to the longitudinal axis of the secondweb.
 9. The method of claim 1, wherein the method is performed by a websplicer configured for a continuous web processing operation.
 10. Themethod of claim 9, wherein the web splicer comprises an unwind stand,the cutting, adhesive applying and curing apparatus, and a storagefestoon.
 11. The method of claim 10, wherein the unwind stand comprisesat least one spindle and at least one idler roller for each spindle. 12.The method of claim 10, wherein the cutting, adhesive applying andcuring apparatus includes a shear assembly, an adhesive applicator, anda curing device including one or more UV-curing light sources allmounted on a chassis for movement laterally of the web.
 13. The methodof claim 1, wherein the cutting of the second web includes moving acutting blade in a direction from a first lateral side of the second webto the second lateral side of the second web, the moving of the cuttingblade also moving an adhesive dispenser that performs the applying ofthe curable adhesive, the moving of the cutting blade also moving atleast one light source that performs the curing.
 14. The method asclaimed in claim 1, wherein the cutting and adhesive applying and curingapparatus is monolithic.
 15. The method as claimed in claim 1, whereinthe cutting is performed by a cutting blade that is mounted for movementin a direction perpendicular to a surface of the second web, and whereinthe applying of the adhesive is performed by an adhesive applyingapparatus that moves with the cutting blade.
 16. The method as claimedin claim 1, wherein the applying of the adhesive is performed by anadhesive applicator that is operatively connected to at least one of ashear blade that performs the cutting of at least one of the first andsecond webs and a curing device that performs the curing of theadhesive.
 17. A method for forming a butt splice to join together aleading edge of a new web of material and a trailing edge of an expiringweb of material as the expiring web runs downstream under tension alonga predetermined path of travel, wherein the butt splice is formed usinga web splicer configured for a continuous web processing operation, saidmethod comprising: securing the new web; securing the expiring web;registering the leading edge of the new web with the trailing edge ofthe expiring web to define a gap between the leading edge and thetrailing edge along a width of new web and a width of expiring web;dispensing a controllable amount of UV-curable liquid adhesive using anadhesive dispensing and curing apparatus, the dispensing supplying theUV-curable liquid adhesive only in the gap between the new and expiringwebs so that a splice is formed without increasing a thickness of theweb at the splice; and curing the UV-curable liquid adhesive using theadhesive dispensing and curing apparatus to form a bond between the newand expiring webs at the splice.
 18. The method of claim 17, wherein thegap measures less than 2millimeters in a longitudinal direction of theweb between a point on the leading edge of the new web and its alignedpoint on the trailing edge of the expiring web.
 19. The method of claim17, wherein the gap measures less than 1millimeter in a longitudinaldirection of the web between a point on the leading edge of the new weband its aligned point on the trailing edge of the expiring web.
 20. Themethod of claim 17, wherein the material is selected from the groupconsisting of film, coated film or material, fiber, fiberglass, paperincluding cardboard, nonwoven web, woven web, and combinations thereof.21. The method of claim 17, wherein the curing includes directing one ormore UV light sources on to the UV-curable liquid adhesive.
 22. Themethod of claim 17, wherein the web splicer comprises an unwind stand,the adhesive dispensing and curing apparatus, a storage festoon, and ananvil positioned substantially parallel to end members of a splicerframe, wherein the adhesive dispensing and curing apparatus includes anadhesive dispenser and a curing apparatus operatively connected to oneanother.
 23. The method of claim 22, wherein the unwind stand comprisesat least one spindle and at least one idler roller for each spindle. 24.The method of claim 22, wherein the adhesive dispensing and curingapparatus includes a shear wheel, an adhesive applicator, and a curingdevice including one or more UV-curing light sources, wherein at leastthe shear wheel and the adhesive applicator are operatively connected toone another.